CAUSE:
These vehicles may experience a discharged battery due to a drain from the after-run cooling fan after engine shut down.

SOLUTION:
Elimination of the ambient temperature sensor from the fan mounting bracket may be necessary to remedy this problem. Please refer to Chrysler Technical Bulletin #08-13-86 for further information.

SYMPTOMS:
The charging system warning lamp comes on, and a “Service battery charging system” message appears. Diagnostic trouble codes B1405 and/or B1516 may also be set in the vehicleʼs computer.

CAUSE:
GM TSB # 06-06-03-006 indicates cranking the engine during low battery voltage conditions may cause the Body Control Module (BCM) to reboot. During the reboot, the battery current sensor may draw excessive current and set either the B1405 or B1516 trouble codes in the BCM.

SOLUTION:
DO NOT automatically replace the BCM, the battery current sensor, or the alternator. If no proven battery or charging system faults exist, reprogram the BCM to the latest service calibration designed to correct this condition.

Remy Quick Tech Tip TA-021: Frayed serpentine belt and/or belt squeal

CAUSE:
Assuming no other typical causes of belt squeal (old/worn belts, etc.), GM TSB #01-06-01-015A indicates some power steering pump brackets may not be properly positioning the power steering pump pulley. Misalignment may result between the power steering pump pulley and the alternator pulley.

SOLUTION:
Adjust the power steering pump bracket position (and replace the serpentine belt), using service manual procedures specified for this vehicle.

SYMPTOMS:
The battery warning lamp comes on during acceleration, or driving uphill.

CAUSE:
Assuming no loose or chafing charging system wires, connections, etc., GM TSB # 06-06-03-008 indicates the problem may result from electromagnetic interference (EMI). The interference results from the closeness of the alternator to the ignition coils.

SOLUTION:
Reprogram the powertrain control module (PCM) to the latest service calibration designed to correct this condition.

SYMPTOMS:
Electrical malfunctions may include a discharged battery, blown fuses, overcharging and low current output at low RPM.

CAUSE:
1) Water may enter the wiring connectors in the engine compartment and in front of the radiator (wiring that joins the body and engine main harness) causing shorted and/or corroded terminals.
2) The hood micro switch may bind causing the under hood lamp to remain on.
3) Low current output at low RPM caused by pulley size.

SOLUTION:
1) Complete inspection and repair of the wiring harness as necessary is strongly recommended. Refer to Ford TSB #91-16-6 for further information.
2) The hood light micro switch is built into the hood release handle under the dash. It is recommended that the switch be checked and shimmed as necessary to eliminate this problem.
3) Ford has issued kit # E92Z010344-D which consists of a smaller alternator pulley, larger crank pulley, drive belt, cover and gasket.

SYMPTOMS:
These vehicles can exhibit milling or grinding of the starter drive pinion and flywheel teeth.

CAUSE:
This is caused by worn crankshaft thrust bearings in the engine. The worn thrust bearing allows the flywheel to float back and forth and to contact the starter drive and actually wear through it.

SOLUTION:
Short of replacing the crankshaft bearings and rebuilding the engine, starter shims (Ford # D7TZ-11N004) are available to move starter back away from the flywheel.

Remy Quick Tech Tip TA-018: Headlamps flicker or dim while driving

CAUSE:
The flickering/dimming condition is sometimes mistaken for a faulty voltage regulator. Usually, this condition is simply a normal operating characteristic due to heavy electrical system loads. On the above vehicles, GM TSB # 05-08-42-001 indicates this normal condition may be amplified by the activation or cycling of the Secondary Air Injection Pump (due to its high current draw).

SOLUTION:
No replacement of the alternator or AIR pump should be made unless a proven fault is found. It is also important to inspect all charging system wiring for loose or corroded connections, poor grounds, etc., which may cause a good voltage regulator to temporarily malfunction.

SYMPTOMS:
Some of these vehicles may experience an intermittent illumination of the charge indicator light on the dash. This usually happens only when the intermittent wipers are in use.

CAUSE:
This is caused by negative voltage being emitted by the wiper motor.

SOLUTION:
GM has released a diode (1H4003), or diode connector kit (12085207) which needs to be installed in the brown wire at the alternator connector to prevent the charge indicator light from coming on.

Remy Quick Tech Tip TA-014: Blown 80-amp sub fuse link

CAUSE:
This can be caused by a blown 80 amp sub fuse link located on the right side of the engine compartment in the relay/fuse box.

SOLUTION:
Disconnect the negative battery cable. Locate the black or clear 80 amp sub fuse link in the fuse box and replace if blown. Check to see if the fuse link is bolted from the bottom before trying to remove.

CAUSE:
These vehicles may exhibit alternator failure due to a failed cooling fan timer relay or ambient air temperature switch. These components are attached to the “L” terminal on the back of the alternator.

SOLUTION:
Whenever the alternator is replaced it is highly recommended that both of the components listed above be checked for proper operation and replaced if necessary.

SYMPTOMS:
Electrical malfunctions may include a discharged battery, blown fuses, overcharging and low current output at low RPM.

CAUSE:
1) Water may enter the wiring connectors in the engine compartment and in front of the radiator (wiring that joins the body and engine main harness) causing shorted and/or corroded terminals.
2) The hood micro switch may bind causing the under hood lamp to remain on.
3) Low current output at low RPM caused by pulley size.

SOLUTION:
1) Complete inspection and repair of the wiring harness as necessary is strongly recommended. Refer to Ford TSB #91-16-6 for further information.
2) The hood light micro switch is built into the hood release handle under the dash. It is recommended that the switch be checked and shimmed as necessary to eliminate this problem.
3) Ford has issued kit # E92Z010344-D which consists of a smaller alternator pulley, larger crank pulley, drive belt, cover and gasket.

Remy Quick Tech Tip TA-008: No charge condition on Honda Accord

VEHICLES AFFECTED:
1982-1983 Honda Accord

SYMPTOMS:
No charge condition.

CAUSE:
This condition may be due to a grounded wire to the “F” terminal of the alternator.

SOLUTION:
Unplug the harness plug from the alternator. Connect the positive lead of a voltmeter to battery positive and the negative lead to the “F” terminal of the plug. There should be no voltage registered on the voltmeter. If voltage is present the “F” wire is grounded and must be repaired. Trace the “F” wire back towards the battery. The ground or short is usually located in the harness connection under the battery tray. Repair the wire as necessary and retest for no voltage.

SYMPTOMS:
Intermittent charging problems that are often related to engine electrical operation and may be difficult to diagnose.

CAUSE:
This condition may be due to the engine electrical harness being rubbed through near the mounting clamp just below the oil pressure sensor.

SOLUTION:
To correct this condition remove the negative battery cable. Remove the harness from the clamp. Carefully inspect wires for any damage and repair as necessary. Wrap any damaged wires with electrical tape or heat shrink tubing. Wrap entire harness again after repairs are completed and secure the harness to the clamp.

SYMPTOMS:
Intermittent, extended (hot) crank time –starter may not disengage after engine startup.

CAUSE:
GM TSB # 06-06-04-049 indicates the Powertain control module (PCM) may need to be reprogrammed.

SOLUTION:
Perform service manual diagnostics related to extended cranking times during hot engine restarts. If no specific causes found (faulty sensor, etc.), reprogram the PCM to the latest calibration designed to address this condition.

CAUSE:
The above conditions may be caused by the alternator positive (+) wiring being trapped between the right hand radiator brace and the alternator. As the engine shifts, the wiring assembly pulls at the eyelet terminal connection at the alternator. This loosens the connection and may cause a no charge condition.

SOLUTION:
To correct the above condition, secure and inspect all wire connections at the alternator and the battery. If terminals and/or wires are damaged repair or replace as necessary.

Remy Quick Tech Tip TA-005: Ford Rangers may exhibit a no start/no charge condition due to a discharged battery

VEHICLES AFFECTED:
1993-1994 Ford Rangers

SYMPTOMS:
-Discharged Battery
-Dim Lights

CAUSE #1:
Ford TSB # 94-9-1 states that the above noted vehicles may exhibit a no start/no charge condition due to a discharged battery. This condition may be caused by the heater fan circuit energizing the alternator when the fan control is left in the on position and the ignition is in the off position.

SOLUTION #1:
To correct this condition, install jumper wire kit (Ford part # F47Z-14A411-A) in cluster according to kits instructions. For further details see Ford TSB # 94-9-1.

CAUSE #2:
Ford TSB # 94-18-8 states that the above noted vehicles may exhibit a discharged battery or dim lights. This condition may be caused by road splash entering the engine department during wet conditions. This road splash can cause the alternator belt to slip resulting in low alternator output and dim lights.

SOLUTION #2:
To correct this condition, Ford has created a new splash shield that must be installed to the left fender apron (Ford part # F37Z-16103-A). For further details see Ford TSB # 94-18-8.

CAUSE:
GM TSB # 04-06-03-012 indicates the battery cable assembly may contact the inner tie rod and center drag link on right turns, causing a direct battery short to ground.

SOLUTION:
First, check for all the usual causes of no start/no crank conditions ( weak battery, etc.). Then, inspect the battery cable assembly near the steering linkage. If necessary, replace the entire POS/NEG battery cable assembly with GM part # 15085788 or equivalent. The new assembly features an additional retainer to prevent the cable assembly from contacting the steering linkage.

CAUSE:
Honda Technical Service Bulletin No. 89-028 states that the above models, equipped with A/C, may experience repeated battery discharge when driven for short trips at low speeds during which
there is a high current demand (A/C, headlights and/or rear window defogger are continuously on).

SOLUTION:
To correct this problem Honda has released two repair kits, One for each year affected. These kits include a new alternator belt and pulley which increases alternator RPM and thus allows for higher current output at low engine RPM.

1988 Kit – 06310-PK-2-A00
1989 Kit – 06310-PK-2-A10

If the above condition is present on your vehicle, installation of the proper kit will insure that your newly purchased alternator operates as intended.

SYMPTOMS:
Severe starter damage including burnout will result from excessive cranking.

CAUSE:
Cranking periods of longer than 3-5 seconds are an indication of fuel delivery and/or glow circuit problems. Diesel engines have very high compression ratios. The starter will be destroyed in a short period of time if allowed to crank for more than a few seconds.

SOLUTION:
Make sure glow plugs are sufficiently hot before cranking. Dash light should indicate that glow plugs are ready. In extreme cold temperatures make sure fuel is not jelled by adding recommended anti-jelling fuel supplements. If long crank times persist, fuel injector and pump circuits must be diagnosed for the starter to operate properly.

CAUSE:
GM TSB # 99-06-03-005A warns that some of the above listed vehicles may have various types of noise (magnetic whine, hum etc.) that can be heard in the passenger compartment. This condition may be more pronounced at idle or other low RPM operations.

This condition can be caused by the normal magnetic pulses from the alternator being transmitted into the passenger compartment by way of the heater inlet and outlet hoses that are attached to the bracket shared by the alternator.

SOLUTION:
GM recommends replacement of the two bolts that hold the heater inlet and outlet pipe adaptor to the bracket with new isolation bolts and heater inlet and outlet pipe adapters.

Replacement of isolation bolts and pipe adapters in effected models will eliminate the noise which may otherwise be diagnosed as a defective alternator.